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Automation, Production Systems, and Computer-Integrated Manufacturing

Automation, Production Systems, and Computer-Integrated Manufacturing

Summary

For advanced undergraduate/ graduate-level courses in Automation, Production Systems, and Computer-Integrated Manufacturing. This exploration of the technical and engineering aspects of automated production systems provides the most advanced, comprehensive, and balanced coverage of the subject of any text on the market. It covers all the major cutting-edge technologies of production automation and material handling, and how these technologies are used to construct modern manufacturing systems.

Table of Contents

Introduction

1

(23)

Production System Facilities

2

(5)

Manufacturing Support Systems

7

(2)

Automation in Production Systems

9

(5)

Manual Labor in Production Systems

14

(3)

Automation Principles and Strategies

17

(4)

Organization of the Book

21

(3)

Manufacturing Operations

24

(37)

Manufacturing Industries and Products

28

(3)

Manufacturing Operations

31

(4)

Product/Production Relationships

35

(5)

Production Concepts and Mathematical Models

40

(8)

Costs of Manufacturing Operations

48

(13)

PART I: AUTOMATION AND CONTROL TECHNOLOGIES

61

Introduction to Automation

66

Basic Elements of an Automated System

63

Advanced Automation Functions

71

Levels of Automation

76

Industrial Control Systems

79

Process Industries versus Discrete Manufacturing Industries

80

Continuous versus Discrete Control

82

Computer Process Control

88

Forms of Computer Process Control

96

Sensors, Actuators, and Other Control System Components

107

Sensors

108

Actuators

111

Analog-to-Digital Conversion

112

Digital-to-Analog Conversion

115

Input/Output Devices for Discrete Data

117

Numerical Control

120

Fundamentals of NC Technology

122

Computer Numerical Control

128

DNC

134

Applications of Numerical Control

137

NC Part Programming

145

Engineering Analysis of NC Positioning Systems

179

Appendix: APT Word Definitions

196

Industrial Robotics

210

Robot Anatomy and Related Attributes

212

Robot Control Systems

218

End Effectors

220

Sensors in Robotics

222

Industrial Robot Applications

222

Robot Programming

230

Engineering Analysis of Industrial Robots

240

Discrete Control Using Programmable Logic Controllers and Personal Computers

257

Discrete Process Control

257

Ladder Logic Diagrams

264

Programmable Logic Controllers

268

Personal Computers Using Soft Logic

275

Part II: MATERIAL HANDLING AND IDENTIFICATION TECHNOLOGIES

Introduction to Material Handling

281

Overview of Material Handling Equipment

282

Considerations in Material Handling System Design

285

The 10 Principles of Material Handling

288

Material Transport Systems

292

Industrial Trucks

293

Automated Guided Vehicle Systems

295

Monorails and Other Rail Guided Vehicles

302

Conveyor Systems

303

Cranes and Hoits

309

Analysis of Material Transport Systems

311

Storage Systems

328

Storage System Performance

329

Storage Location Strategies

331

Conventional Storage Methods and Equipment

332

Automated Storage Systems

335

Engineering Analysis of Storage Systems

344

Automatic Data Capture

357

Overview of Automatic Identification Methods

358

Bar Code Technology

361

Other A DC Technologies

370

PART III: MANUFACTURING SYSTEMS

Introduction to Manufacturing Systems

375

Components of a Manufacturing System

376

Classification of Manufacturing Systems

381

Overview of the Classification Scheme

388

Manufacturing Progress Functions (Learning Curves)

392

Single Station Manufacturing Cells

397

Single Station Manned Workstations

398

Single Station Automated Cells

399

Applications

404

Analysis of Single Station Cells

409

Group Technology and Cellular Manufacturing

420

Part Families

422

Parts Classification and Coding

425

Production Flow Analysis

431

Cellular Manufacturing

434

Application Considerations in Group Technology

439

Quantitative Analysis in Cellular Manufacturing

442

Flexible Manufacturing Systems

460

What is an FMS?

462

FMS Components

469

FMS Applications and Benefits

480

FMS Planning and Implementation Issues

485

Quantitative Analysis of Flexible Manufacturing Systems

487

Manual Assembly Lines

514

Fundamentals of Manual Assembly Lines

516

Alternative Assembly Systems

523

Design for Assembly

524

Analysis of Single Model Assembly Lines

525

Line Balancing Algorithms

534

Mixed Model Assembly Lines

540

Other Considerations in Assembly Line Design

552

Transfer Lines and Similar Automated Manufacturing Systems

566

Fundamentals of Automated Production Lines

565

Applications of Automated Production Lines

575

Analysis of Transfer Lines with No Internal Storage

579

Analysis of Transfer Lines with Storage Buffers

587

Automated Assembly Systems

601

Fundamentals of Automated Assembly Systems

602

Design for Automated Assembly

606

Quantitative Analysis of Assembly Systems

610

PART IV: QUALITY CONTROL SYSTEMS

Introduction to Quality Assurance

631

Quality Defined

633

Traditional and Modern Quality Control

635

Taguchi Methods in Quality Engineering

638

ISO 9000

648

Statistical Process Control

654

Process Variability and Process Capability

655

Control Charts

658

Other SPC Tools

667

Implementing Statistical Process Control

672

Inspection Principles and Practices

681

Inspection Fundamentals

682

Sampling versus 100% Inspection

687

Automated Inspection

692

When and Where to Inspect

694

Quantitative Analysis of Inspection

698

Inspection Technologies

711

Inspection Metrology

712

Contact versus Noncontact Inspection Techniques

717

Conventional Measuring and Gaging Techniques

718

Coordinate Measuring Machines

720

Surface Measurement

736

Machine Vision

738

Other Optical Inspection Techniques

745

Noncontact Nonoptical Inspection Technologies

747

PART V: MANUFACTURING SUPPORT SYSTEMS

Product Design and CAD/CAM in the Production System

753

Product Design and CAD

755

CAD System Hardware

761

CAM, CAD/CAM, and CIM

764

Quality Function Deployment

767

Process Planning and Concurrent Engineering

775

Process Planning

776

Computer-Aided Process Planning (CAPP)

782

Concurrent Engineering and Design for Manufacturing

785

Advanced Manufacturing Planning

791

Production Planning and Control Systems

796

Aggregate Production Planning and the Master Production Schedule

798

Material Requirements Planning (MRP)

800

Capacity Planning

806

Shop Floor Control

808

Inventory Control

814

Manufacturing Resource Planning (MRP II)

822

Just-In-Time Production Systems

823

Lean Production and Agile Manufacturing

832

Lean Production

833

Agile Manufacturing

835

Comparison of Lean and Agile

843

Excerpts

Preface The first edition of this book was published in 1980 under the titleAutomation, Production Systems, and Computer-Aided Manufacturing.A revision was published in 1987 with about 200 more pages and a slightly different title:Automation, Production Systems, and Computer Integrated Manufacturing.The additional pages expanded the coverage of topics like industrial robotics, programmable logic controllers, material handling and storage, and quality control. But much of the book was very similar to the 1980 text. By the time I started work on the current volume (technically the second edition of the 1987 title, but in fact the third generation of the 1980 publication), it was clear that the book was in need of a thorough rewriting. New technologies had been developed and existing technologies had advanced, new theories and methodologies had emerged in the research literature, and my own understanding of automation and production systems had grown and matured (at least I think so). Readers of the two previous books will find this new volume to be quite different from its predecessors. Its organization is significantly changed, new topics have been added, and some topics from the previous editions have been discarded or reduced in coverage. It is not an exaggeration to say that the entire text has been rewritten (readers will find very few instances where I have used the same wording as in the previous editions). Nearly all of the figures are new. It is essentially a new book. There is a risk in changing the book so much. Both of the previous editions have been very successful for Prentice Hall and me. Many instructors have adopted the book and have become accustomed to its organization and coverage. Many courses have been developed based on the book. What will these instructors think of the new edition, with all of its new and different features? My hope is that they will try out the new book and find it to be a significant improvement over the 1987 edition, as well as any other textbook on the subject. Specifically, what are the changes in this new edition? To begin with, the organization has been substantially revised. Following two introductory chapters, the book is organized into five main parts: Automation and control technologies:Six chapters on automation, industrial computer control, control system components, numerical control, industrial robotics, and programmable logic controllers. Material handling technologies:Four chapters covering conventional and automated material handling systems (e.g., conveyor systems and automated guided vehicle systems), conventional and automated storage systems, and automatic identification and data capture. Manufacturing systems:Seven chapters on a manufacturing systems taxonomy, single station cells, group technology, flexible manufacturing systems, manual assembly lines, transfer lines, and automated assembly. Quality control systems:Four chapters covering quality assurance, statistical process control, inspection principles, and inspection technologies (e.g., coordinate measuring machines and machine vision). Manufacturing support systems:Four chapters on product design and CAD/CAM, process planning, production planning and control, and lean production and agile manufacturing. Other changes in organization and coverage in the current edition, compared with the 1987 book, include: Expanded coverage of automation fundamentals, numerical control programming, group technology, flexible manufacturing systems, material handling and storage, quality control and inspection, inspection technologies, programmable logic controllers. New chapters or sections on manufacturing systems, single station manufacturing systems, mixed-model assembly line analysis, quality assurance and statistical process control, Taguchi methods,